Infotainment system for automotive giant turns it up with smart automation
Automotive Electronics
A North American manufacturing line produces critical and complex electronic assemblies for a major automotive manufacturer, but the line was highly manual and labor intensive, and required dozens of human touch points. The company selected Bright Machines Microfactories to speed up production and improve product quality.
The problem
A major automotive company relies on a North American EMS assembly and inspection line for their infotainment electronics consoles – vehicle systems that enable radio, navigation, telematics, multimedia and internet-based applications to be centrally controlled. Prior to Bright Machines, the line relied on manual labor and had 58 touch points that made it challenging to maintain continuity. That much human interaction meant that outcomes were largely dependent on the expertise and ability of the operator on-shift, which can decline as the shift goes on and operators become fatigued. The emphasis on manual labor limited units produced per hour and had little ability to monitor performance in real time, ensure consistent quality, and identify and resolve any issues on the line and adjust quickly.
The solution
With labor costs, quality, traceability of materials and processes important metrics of their success, this business realized they needed to rethink their automation strategy. Turning to Bright Machines, the manufacturer replaced a manual assembly process with an automated, software-defined Bright Machines Microfactory to produce infotainment electronics consoles faster, with better yield and reduced defect rates. Their solution involves three Bright Robotics Cells performing pick and place, screwing processes, as well as final label application.
The Bright Machines Microfactory allows the line to maintain the same rate of production hour by hour, without having to rely on the consistency of a human operator working a long shift. It also meant that the manufacturer eliminated the need to train operators to perform specific tasks, thus minimizing expertise required for employees on the line while still meeting the extremely high-quality demands of the end customer.
The results
With the deployment of their microfactory, this automotive manufacturer was able to dramatically increase yield and quality while reducing headcount and defect rates.
Results include:
- Unit production increased 33% per hour
- The new microfactory required only 25% of the human touches compared to the previous, manual process
- Defect rates reduced by 88%
- 50% reduction in assembly-line staff
And these results are only representative of their North American manufacturing line. Because the Bright Machines Microfactory is so easily scaled, we have since implemented additional lines for this same customer, reusing the same solution in other geographies.
For more information, check out:
- Product page: Bright Machines Microfactories
- Video: Microfactories: Explained
- Video library: More Bright Machines Videos
- Webinar: EMS 2.0: How To Remain Competitive in Electronics Manufacturing
- Blog: Auto Industry Takes Moore’s Law for a Drive
- Blog: BMW i Ventures Joins the Bright Machines Journey
- Blog: Instant Factories
Contact us to find out how Bright Machines Microfactories can transform your electronics assembly and inspection line.